Toro 5200-D manual

Operator ’ s Manual English (EN, GB) Form No. 3353–130 Reelmaster 5200-D/5400-D T wo-Wheel and Four-Wheel Drive T raction Units 03540—250000001 and Up 03543—250000001 and Up 03544—250000001 and Up[...]

2 All Rights Reserved Printed in the USA W 2005 by The T oro Company 81 1 1 Lyndale A venue South Bloomington, MN 55420-1 196 CALIFORNIA Proposition 65 W arning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer , birth defects, and other repr oductive harm. W arning Important The engine in this [...]

3 Introduction Read this manual carefully to learn how to operate and maintain your product properly . The information in this manual can help you and others avoid injury and product damage. Although T oro designs and produces safe products, you are responsible for operating the product properly and safely . Whenever you need service, genuine T oro[...]

4 Preparation • While mowing, always wear substantial footwear , long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. • Thoroughly inspect the area where the equipment is to be used and remove all ob[...]

5 • Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Slow down and use caution when making turns and crossing roads an[...]

6 – Do not drive close to sand traps, ditches, creeks, or other hazards. – Reduce speed when making sharp turns. A void sudden stops and starts. – When near or crossing roads, always yield the right-of-way . – Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine. • The grass basket[...]

7 Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger . Replace any decal that is damaged or lost. 107-8841 93-6693 1. Hazard to hands–pinch points 2. Stop reels before touching 104-2052 1. See operator’s manual[...]

8 104-9296 1. Throttle—slow 2. Throttle—fast 3. Reels raised & off 4. Reels lowered and on when enabled—forward and backlap 5. Reels—enabled 6. Reels disabled—lift only 7. Reels disabled—lift and lower 8. Headlights (optional) 9. Headlights—on 10. Headlights—off 1 1. Read operator’s manual 104-9298 1. Read operator’s manual [...]

9 106-9224 1. Warning—read the Operator’s Manual . 2. Cutting hazard of hand and foot—stop the reels before touching. 93-6697 (Model 03544 only) 1. Read operator’s manual 2. Lubrication point 3. Time interval 98-9335 1. Cutting dismemberment hazard–stay away from moving parts 93-6696 1. Danger–spring loaded device 2. Read operator’s m[...]

10 93-6680 1. Diesel fuel 105-7506 1. Read the Operator’s Manual 2. Engine—stop 3. On 4. Engine—preheat 5. Engine—start 93-1263 1. Read operator’s manual 2. T o engage parking brake–connect pedals with locking pin, push down on both pedals and pull parking brake latch out. 3. T o release parking brake–press both pedals until parking b[...]

11 104-9294 1. Read the Operator ’s Manual. 2. Do not tow the machine. 3. Warning—read the Operator’s Manual. 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Warning—keep bystanders a safe distance from the machine. 6. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machi[...]

12 Specifications General Specifications Engine Kubota three cylinder , 4 cycle liquid cooled diesel engine. 25 hp @ 3000 rpm for Reelmaster 5200 and 31.5 hp @ 3000 rpm for Reelmaster 5400. Both governed to 3200 rpm. 68.5 cu. in. (1 123 cc) displacement. Heavy duty , 3-stage, remote mounted air cleaner . High water temperature shutdown switch. Cool[...]

13 Measurements Width of Cut 95 in. Overall Width T ransport Outside of front tires Outside of rear tires 87 in. 87 in. 52-1/2 in. Overall Length Without grass baskets With grass baskets 103-1/2 in. 1 16 in. Height Without ROPS installed With ROPS installed 56-1/2 in. 85 in. Recommended Height of Cut 5 Blade Cutting Unit 8 Blade Cutting Unit 1/2–[...]

14 Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. W ithout these parts, total setup cannot be completed. Description Qty . Use Locking hood switch Lock washer Nut Key Hood latch brack[...]

15 2 1 Figure 1 1. Positive battery cable 2. Negative battery cable Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery . W arning Battery terminals or metal tools could short against metal tractor components, causing sparks. Sparks can cause the battery gasses to expl[...]

16 5. Adjust latch bracket, until aligned with switch latch, then tighten capscrews. 6. Rotate latch to locked and unlocked position with key . Remove key and store in memorable place. 7. Close hood. Replacing the Panel Fasteners 1. Remove fasteners securing left front corner of floor panel and left end of access panel to frame (Fig. 4). 1 2 Figure[...]

17 5. Align the mounting shaft of the cutting unit with the pivot tube on the carrier frame. Insert the shaft into the tube (Fig. 8). 1 2 3 4 5 6 Figure 8 1. Cutting unit mounting shaft 2. Carrier frame pivot tube 3. Thrust washer 4. Flat washer 5. Lock washer 6. Capscrew 6. Secure shaft in pivot tube with a thrust washer , flat washer , lock washe[...]

18 Adjusting the T urf Compensation Spring Note: This adjustment is needed for Cutting Unit Models 03527 and 03528 only . The turf compensation spring (Fig. 12), connecting carrier frame to cutting unit, controls the amount of fore-aft rotation available. The T urf Compensation Spring also transfers weight from the front to rear roller . (This help[...]

19 Installing the Rear Weight The Reelmaster 5200-D & 5400-D T raction Units comply with CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 Standards when equipped with rear weight and 90 lb. of calcium chloride ballast is added to rear wheels. Use chart below to determine combinations of weight required. Order parts from you[...]

20 Before Operating If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine. Caution Checking the Engine Oil The engine is shipped with o[...]

21 1 Figure 16 1. Expansion tank 2. If coolant level is low , remove expansion tank cap and replenish the system. Do not overfill . 3. Install expansion tank cap. Filling the Fuel T ank 1. Remove fuel tank cap (Fig. 17). 2. Fill tank to about one inch below top tank, not filler neck with No. 2 diesel fuel. Then install cap. Danger Under certain con[...]

22 Checking the Hydraulic Fluid The machines reservoir is filled at the factory with approximately 8 gallons of high quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter . The recommended replacement fluid is: T oro Premium T ransmission/Hydraulic T ractor Fluid (A vailable in 5 gal[...]

23 4. Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole. 5. Install all plugs. Checking Reel to Bedknife Contact Each day before operating, check reel to bedknife contact, regardless if quality of cut had previously been acceptable. There must be light contact across the full length of t[...]

24 Operation Note: Determine the left and right sides of the machine from the normal operating position. If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adj[...]

25 1 2 3 4 5 7 6 Figure 24 1. Traction speed limiter 2. Reel control light 3. Speedometer 4. Brake pedals 5. Parking brake latch 6. Locking pin 7. Key switch Engine Coolant T emperature W arning Light The light (Fig. 25) illuminates and engine shuts down when coolant reaches a dangerously high temperature. Throttle Control Move control (Fig. 25) fo[...]

26 Reel Speed Controls The reel speed controls (Fig. 27) control the RPM of front and rear cutting units. #1 position is for backlapping. Remaining settings are for mowing operations. See section in manual for operating instructions. 1 Figure 27 1. Reel speed controls Hour Meter The hour meter (Fig. 28) shows total hours that machine has been opera[...]

27 Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank co[...]

28 Adjusting the Lift Arm Down Pressure The down pressure spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions. Increased down pressure will help keep the cutting units on the ground when mowing at higher speeds and helps maintain a uniform height-of-cut in rough conditions or in areas of thatch build up.[...]

29 3. Attach the other end of the towing device to a vehicle that is capable of towing the machine safely and at speeds below 3 mph. 4. An operator must be on the machine to steer it and keep the traction pedal fully depressed in the forward position while towing. 5. When towing is completed, reinstall driveshaft as shown in Figure 33. The splines [...]

30 1 Figure 36 1. Wire harness and connectors 3. Connect the Diagnostic ACE display connector to the harness connector (Fig. 37). Make sure correct overlay decal is positioned on Diagnostic ACE display . 4. T urn the key switch to the ON position, but do not start machine. 1 Figure 37 1. Diagnostic ACE Note: The red text on the overlay decal refers[...]

31 If the output LED’ s are on as specified, but the machine does not function properly , this indicates a non–electrical problem. Repair as necessary . Note: Due to electrical system constraints, the output LED’ s for “ST AR T”, “PREHEA T” and “ETR/AL T” may not blink even though an electrical problem may exist for those function[...]

32 Logic Chart Raise (T o turn around front & Raise (T o turn around front & A=OUTPUT ON IF REELS WERE PREVIOUSL Y RUNNING 2) Start 0) Controller OK 1) Preheat 3) Run (No operator) 4) Lower (T o turn around) Lower (All units when disabled) Lower / Mow–Front 5) Mow 6) Raise (transport) Raise (T o turn around front) 7) Backlap Front 8) Back[...]

33 Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Important Refer to your engine operator ’ s manual for additional maintenance procedures. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt tension.[...]

34 Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. T ues. Wed. Thurs. Fri. Sat. Sun. Check safety interlock operation. Check brake operation. Check engine oil and fuel level. Drain the water/fuel separator . Check the air filter restriction indicator . Check the radiator and screen for d[...]

35 Service Interval Chart If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition switch and lower the cutting units to the ground before servicing or making adjustments to the machine. Caution Greasing the Bearing and Bushings The machine [...]

36 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45[...]

37 General Air Cleaner Maintenance • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps. • Service the air cleaner filter only when the service indicator requires it. Changing the air filter before it is necessary only increases the chance[...]

38 Engine Oil and Filter Change oil and filter initially after the first 50 hours of operation, thereafter change oil and filter every 150 hours. 1. Remove drain plug (Fig. 48) and let oil flow into drain pan. When oil stops, install drain plug. 1 Figure 48 1. Engine oil drain plug 2. Remove oil filter (Fig. 49). Apply a light coat of clean oil to [...]

39 3. Loosen the hose clamps at both ends of the filter and pull fuel lines off filter . 1 2 2 Figure 51 1. Fuel filter 2. Hose clamps 4. Slide hose clamps onto ends of fuel lines. Push fuel lines onto fuel filter and secure them with hose clamps. Be sure arrow on side of filter points toward the injection pump. Danger Under certain conditions, die[...]

40 3. Slightly raise oil coolers and pivot forward (Fig. 54). Clean both sides of oil coolers and radiator area thoroughly with compressed air . Pivot oil coolers back into position. 2 1 3 Figure 54 1. Reel oil cooler 2. Radiator 3. Transmission oil cooler 4. Install screen and close hood. Servicing the Engine Belts Check condition and tension of a[...]

41 1 Figure 57 1. Injection pump lever arm Changing the Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local T oro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1. T urn engine off and rais[...]

42 Checking the Hydraulic Lines and Hoses Daily , check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear , loose fittings, weather deterioration and chemical deterioration. Make all necessary repairs before operating. Hydraulic fluid escaping under pressur e can penetrate skin and cause injury . • Make sure all hyd[...]

43 Adjusting the Cutting Unit Lift Rate The cutting unit lift circuit is equipped with (3) adjustable valves used to ensure the cutting units do not raise too quickly and bang against lift stops. Adjust cutting units as follows: Center Cutting Unit 1. Locate valve behind access panel above operator ’ s platform (Fig. 62). 2. Loosen setscrew on va[...]

44 Checking and Adjusting the T raction Linkage Due to normal wear in the control linkage and hydrostatic transmission, an increased amount of force may be required to return the transmissions to neutral. Periodically check the machine. 1. Park machine on a level surface, lower cutting units to the floor and shut engine off. 2. Connect brake pedals[...]

45 6. Before starting the engine after changing transmission fluid, disconnect the run (ETR) solenoid on the engine, and crank the engine several times for 15 seconds. This allows the charge pump to fill the transmission with fluid before the engine is started. 1 2 Figure 67 1. Transmission suction line 2. Transmission oil filter Replacing the T ra[...]

46 1 Figure 69 1. Tie rods 3. When toe-in is correct, tighten jam nuts against tie rods. Models 03544 only 1. Rotate the steering wheel so the rear wheels are straight ahead. 2. Remove the cotter pin and slotted hex nut from either tie rod ball joint. Use a ball joint fork and remove the tie rod ball joint from the axle case support. 3. Loosen clam[...]

47 posts and cable connectors with Grafo 1 12X (skin-over) grease (T oro Part No. 505-47) or petroleum jelly to prevent corrosion. Fuses There are 4 fuses in the machines electrical system. They are located below control panel (Fig. 71 and 72). 1 Figure 71 1. Fuses Figure 72 Optional Lighting Important If optional lighting is be added to the tracti[...]

48 Danger Changing the engine speed while backlapping may cause the reels to stall. • Never change the engine speed while backlapping. • Only backlap at idle engine speed. 5. Set both reel speed controls to position 1 1. Select either front or rear on backlap switch to determine which units to backlap. Danger T o avoid personal injury , be cert[...]

49 Electrical Schematic ST ART RELA Y 2A RUN (ETR) SOLENOID OUTPUTS INPUTS B A I Y X RUN ST ART S 3C 2B 3M ENGINE WA TER TEMP SENSOR STAR T – KEY SWITCH ST ARTER 1S 1B 2S 3S 4S 1E 5S 6S 7S 1F 1H NEUTRAL SENSOR SEA T SENSOR 2C 2E 3G 1N 1G AL TERNA TOR KEY SWITCH PULL (B) HOLD (A) FIELD (R) OUTPUT ( B) GLOW PLUGS 2 1 4 5 WRNG LIGHTS (L) HOUR METER [...]

50 Hydraulic Schematic C2 FD1 C1 P P3 P1 P2 TEST PORT FOR FRONT UNITS (3) STEERING CYLINDER FORW ARD SIDE OF CLOSED LOOP SUNSTRAND M25 1.5 IN3 /REV ”A” ”A” SYSTEM RELIEF 3625 PSI OUTPUT SHAFT TO DIFFERENTIAL INPUT SHAFT 3200 RPM MAX OIL COOLER DIFFERENTIAL HOUSING T FOR REAR[R]UNITS 1250 PSI 3 AUX STRAINER IN T ANK 100 MESH IN OUT TRW HGF 1[...]

51 Preparation for Seasonal Storage T raction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all traction unit tires to 15–20 psi. 3. Check all fasteners for looseness; tighten as necessary . 4. Grease or oil all grease fittings and pivot points. W ipe up any excess lubricant. 5. Ligh[...]

The T oro General Commercial Products W arranty A T wo-Y ear Limited W arranty Conditions and Products Covered The T oro Company and its af filiate, T oro W arranty Company , pursuant to an agreement between them, jointly warrant your T o ro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500[...]